Physical support pads as paired pallet slip-lock systems

ABSTRACT

The present invention is directed to physical support pads constructed as paired pallet slip-lock systems that offer flexible sizing, adjustable shapes for changing fitness needs, as well as offer quick and secure re-configuration. The slip-lock systems of the present invention afford a longitudinal interlocking mechanism between paired structural pallet segments that offers not only fastening security, but also longitudinal separation. In particular, the present invention provides physical support pads with highly responsive fitness properties, such as energy return and joint protection, anti-slip characteristics, stack ability, and increased durability to withstand active and functional fitness needs.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application No. 63/345,006, filed on May 23, 2022; the entirety of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

With the advent of ergonomics, and realization by the public of their general utility, support pads have gained increasing favorability. Moreover, these physical support pads have shown an expansion in their functional use: from improving work comfort or fatigue reduction, to physical fitness and the practice of yoga. In fact, these pads have taken a number of forms in the fitness realm, including rollable and non-rollable mats, as well as puzzle-piece floor cushions that assemble from two or more pieces.

Mats are certainly useful as a support pad, but are static in nature, bulky to manipulate, unfriendly to transport, and generally unable to adjust to different demands of ever-changing fitness. Puzzle-piece floor cushions have an advantage over static mats by creating flexible sizing, as well as adjustable shapes for the changing fitness needs. Although puzzle-piece floor cushions solve the adjustability issue, they are often made of sub-optimal materials given their intended purpose is outside the fitness arena, and therefore are not designed to possess the properties suitable for use in fitness. Moreover, and more importantly, puzzle-piece floor cushions require cumbersome effort to separate and reposition during active fitness activity given their vertical interlock requirements that are not amenable to the functional fitness demands necessitating the ability to move quickly from one physical move to another.

Functional fitness, and activities like yoga, demand the ability to move quickly from one move/position to another, and coincidentally sliding longitudinally across the floor from one move/position to another. However, the existing support pads are not designed to accommodate such movement nor quick re-configuration, interrupting the activity or even causing injury.

As such, there remains a need for improved physical support pads that offer flexible sizing, adjustable shapes for changing fitness needs, as well as offer quick and secure re-configuration. In particular, there is a need for such physical support pads with highly responsive fitness properties, anti-slip characteristics, stack ability, and increased durability to withstand active and functional fitness needs.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to physical support pads constructed as paired pallet slip-lock systems that offer flexible sizing, adjustable shapes for changing fitness needs, as well as offer quick and secure re-configuration. The slip-lock systems of the present invention afford a longitudinal interlocking mechanism between paired structural pallet segments that offers not only fastening security, but also longitudinal separation. In particular, the present invention provides physical support pads with highly responsive fitness properties and increased durability to withstand active and functional fitness needs.

One aspect of the present invention is directed to a physical support pad constructed as a paired pallet slip-lock system comprising at least two structural pallet segments of expanded polyurethane foam wherein the two structural pallet segments comprise a first structural pallet segment shaped to incorporate a slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity; and a second structural pallet segment shaped to incorporate a slip-lock anchor defined to match the slip-lock cavity comprising two anchor tabs on each side of the slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position; wherein the first and second structural pallets are suitably flexible such that the slip-lock anchors of the second structural pallet segment may longitudinally slip past the anchor toggles of the first structural pallet segment to interlock as a paired pallet, and wherein the two segments longitudinally separate only when the release force exceeds the force required to longitudinally flex one or more of the anchor toggles or the anchor tabs.

Another aspect of the present invention is directed to a travel physical support pad comprising a physical support pad of the present invention, wherein the pad diameter across any axis of symmetry is about 10 inches, e.g., suitable in size for carrying during travel, but large enough to be remain useful for its intended purpose.

Another aspect of the present invention is directed to a physical support pad expansion kit comprising one or more expansion structural pallet segments for use in conjunction with the physical support pad of the present invention, wherein each expansion structural pallet segment comprises at least one of:

-   -   a slip-lock cavity; or     -   a slip-lock anchor.

BRIEF DESCRIPTION OF THE FIGURES

Advantages of the present systems and kits will be apparent from the following detailed description, which description should be considered in combination with the accompanying figures, which are not intended to limit the scope of the invention in any way.

FIG. 1 depicts a top down perspective of an exemplary first structural pallet segment shaped to incorporate a slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity.

FIG. 2 depicts a top down perspective of an exemplary second structural pallet segment shaped to incorporate a slip-lock anchor defined to match the slip-lock cavity of FIG. 1 comprising two anchor tabs on each side of the slip-lock anchor.

FIG. 3 depicts a top down perspective of an interlocking paired pallet showing the first structural pallet segment of FIG. 1 and the second structural pallet segment of FIG. 2 interlocking wherein the first and second structural pallets are suitably flexible such that the slip-lock anchor of the second structural pallet segment may longitudinally slip past the anchor toggles of the first structural pallet segment to interlock as a paired pallet wherein the anchor tabs will be positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position.

FIG. 4 depicts a top down perspective of an interlocked paired pallet showing the first structural pallet segment of FIG. 1 and the second structural pallet segment of FIG. 2 interlocked wherein the first and second structural pallets are suitably flexible such that the slip-lock anchor of the second structural pallet segment may longitudinally slip past the anchor toggles of the first structural pallet segment to interlock as a paired pallet wherein the anchor tabs are positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position. The white space depicts the connection in an overemphasized way to more clearly see the paired pallets.

FIG. 5 depicts a top down perspective of the separation of the interlocked paired pallet of FIG. 4 , wherein two segments longitudinally separate only when the release force exceeds the force required to longitudinally flex or toggle one or more of the anchor toggles outward as indicated by arrow showing outward directional toggling and the double arrow showing the longitudinal separation of the interlocked pallets.

FIG. 6 depicts a top down perspective of single hexagonal structural pallet segment shaped to incorporate a slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity; and shaped to incorporate a slip-lock anchor defined to match the slip-lock cavity comprising two anchor tabs on each side of the slip-lock anchor.

FIG. 7 depicts a top down perspective of two hexagonal structural pallet segments of FIG. 6 interlocking, wherein the anchor tabs will be positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to physical support pads constructed as paired pallet slip-lock systems that offer flexible sizing, adjustable shapes for changing fitness needs, as well as offer quick and secure re-configuration. The slip-lock systems of the present invention afford a longitudinal interlocking mechanism between paired structural pallet segments that offers not only fastening security, but also longitudinal separation. In particular, the present invention provides physical support pads with highly responsive fitness properties, such as energy return and joint protection and increased durability to withstand active and functional fitness needs.

In particular, the physical support pads of the present invention utilize slip-lock systems of the present invention that offer secure fastening of paired structural pallet segments during active and functional fitness. The interlock system of the present invention provides stability of the interlocked pallet segments and helps keep the segments together to retain configurations during exercise like yoga, but also allows quick and secure longitudinal reconfiguration of the segments for functional fitness allowing quick movement from one physical move to another by sliding pallet segments together or apart in the plane of the floor, e.g., sliding the segments across the floor toward and away from each other to interlock and separate the segments, respectively; in stark contrast to existing support pads.

The present invention, including pads, systems and kits will be described with reference to the following definitions that, for convenience, are set forth below. Unless otherwise specified, the below terms used herein are defined as follows:

I. Definitions

As used herein, the term “a,” “an,” “the” and similar terms used in the context of the present invention (especially in the context of the claims) are to be construed to cover both the singular and plural unless otherwise indicated herein or clearly contradicted by the context.

The term “about” is used herein in reference to the degree or extent of the term which it modifies, and that such extent may be 100% or near to but not exactly 100% of the modified term; industry accepted standards will assist in defining the quantitative aspects of how “near” 100% is defined. In particular embodiments, the term “about” indicates ±2%, ±1% or ±0.5%. In a particular embodiment, for example, the language “about 1 inch” would be exactly 1 inch; and in an alternative particular embodiment, for example, the language “about 1 inch” would mean 1 inch±2%, 1 inch±1%, or 1 inch±0.5%.

The language “anchor tabs” is used herein to describe the extending projections positioned one on each side of the slip-lock anchor which act to flex/toggle the anchor toggles of the slip-lock cavity when the slip-lock anchor is longitudinally moved inward into the slip-lock cavity and afford interlocking with the anchor toggles that are positioned under/outside of the anchor tabs to fix the position of the slip-lock anchor. In certain embodiments, the interlocked slip-lock anchor may move longitudinally outward when the release force exceeds the force required to (longitudinally) flex one or two of the anchor tabs.

The language “anchor toggle” is used herein to describe the small extending protrusions positioned one on each side of the slip-lock cavity which flex or toggle longitudinally in both inward and outward directions: (1) allowing a slip-lock anchor to move inward toward the cavity by toggling inward and offering little resistance and then interlocking under/outside of the anchor tabs to fix the position of the slip-lock anchor, and (2) allowing the interlocked slip-lock anchor to move outward by toggling outward and releasing one or more fixed anchor tabs when the release force exceeds the force required to (longitudinally) flex one or two of the anchor toggles.

The language “and/or” is used herein to mean both “and” in the conjunctive form and “or” in the disjunctive form.

The language “e-TPU” or “expanded thermoplastic polyurethane” is art-recognized, and is used herein to describe the material composition of the foam particles and related molded foam selected from one or more of a polyether polyurethane, a polyester polyurethane, a polycarbonate polyurethane, and a polycaprolactone polyurethane. In certain embodiments, the e-TPU is a polyether polyurethane. In certain embodiments, the e-TPU is a polyester polyurethane.

The term “facet” is used herein to describe a side or face of a two-dimensional shape. For example, a hexagon has six facets.

The term “longitudinal” is used herein to describe the direction of movement of the structural pallets of the invention in one direction and within a single plane. For example, sliding pallet segments together or apart in the plane of the floor would described herein as sliding longitudinally or longitudinal movement, e.g., sliding the segments across the floor toward and away from each other to interlock and separate the segments, respectively. As such, longitudinal separation would be describe the act of sliding pallet segments apart in the plane of the floor.

The language “expanded polyurethane foam” is used herein to describe the material composition of the polyurethane foam of the present invention selected from one or more of a polyether polyurethane, a polyester polyurethane, a polycarbonate polyurethane, and a polycaprolactone polyurethane. In certain embodiments, the expanded polyurethane foam is a polyether polyurethane. In certain embodiments, the expanded polyurethane foam is a polyester polyurethane. In a particular embodiment, the expanded polyurethane foam is a molded expanded thermoplastic polyurethane, i.e., e-TPU). In a particular embodiment, the expanded polyurethane foam is an expanded free-rise polyurethane, e.g., a thermoset elastomeric polyurethane, e.g., made from a two component mixture; which may be then skived into layers and/or a desired shape.

The terms “paired” is used herein to describe matching male and female areas, represented by a slip-lock cavity and a slip-lock anchor that are the same size, i.e., matching.

The language “release force” is used herein to describe the total force required to overcome/exceed the interlocking force created by the anchor toggles and anchor tabs that would release the interlock and separate the two interlocked structural pallet segments.

The term “resilience” is art-recognized, and used herein to describe the physical characteristic that the elasticity of the material can be maintained under continuous load.

The language “structural pallet” is used herein to describe a physical platform that offers support and padding, which is constructed with a selected thickness and rigidity to absorb a defined amount of force, e.g., based on the material composition (i.e., expanded polyurethane foam)

The term“segment,” as used in the expression “structural pallet segment,” is used herein to describe a defined fraction of the physical support pad that when interlocked together compose a physical support pad constructed as a paired pallet slip-lock system comprising at least two structural pallet segments of expanded polyurethane foam.

The term “shaped” is used herein to describe the action of creating a shape or design through the use of cutting (or skiving) or use of a mold, or by subsequent cutting of a molded plank.

The language “slip-lock anchor” is used herein to describe the male component of the paired pallet slip-lock systems of the present invention. The slip-lock anchor defined to match the slip-lock cavity, and comprises two anchor tabs on each side of the slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position.

The language “slip-lock cavity” is used herein to describe the female component of the paired pallet slip-lock systems of the present invention. The slip-lock cavity is defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity.

The language “yoga accessory” is used herein to describe a function of the physical support pads of the invention offering an anti-slip and joint support aid during the practice of yoga. The structural pallet segments can be used in a single layer atop a conventional rectangular yoga mat, or even stacked to provide enhanced slip resistance and joint and body support.

II. Physical Support Pads of the Invention

One embodiment of the present invention provides a physical support pad constructed as a paired pallet slip-lock system comprising at least two structural pallet segments of expanded polyurethane foam wherein the two structural pallet segments comprise

-   -   a first structural pallet segment shaped to incorporate a         slip-lock cavity defined by a narrowing cavity with two anchor         toggles positioned one on each side of the cavity; and     -   a second structural pallet segment shaped to incorporate a         slip-lock anchor defined to match the slip-lock cavity         comprising two anchor tabs on each side of the slip-lock anchor,         wherein the anchor tabs are positioned such that the anchor         toggles and the anchor tabs are adjacent when the paired pallet         segments are in interlocked position;         wherein the first and second structural pallets are suitably         flexible such that the slip-lock anchors of the second         structural pallet segment may longitudinally slip past the         anchor toggles of the first structural pallet segment to         interlock as a paired pallet, and wherein the two segments         longitudinally separate only when the release force exceeds the         force required to longitudinally flex one or more of the anchor         toggles or the anchor tabs.

In certain embodiments of the present invention, the release force required to separate two segments longitudinally is not achieved by pulling one segment (i.e., frictional gravitational force created by the weight and frictional resistance of the dragging of interlocked segments is not sufficient to result in a release force that exceeds the force required to longitudinally flex one or more of the anchor toggles or the anchor tabs). In certain embodiments, the gravitational frictional force may contribute to application of release force.

In certain embodiments of the present invention, each slip-lock cavity and slip-lock anchor are positioned on different facets of the structural pallet segments.

In certain embodiments of the present invention, structural pallet segments are any shape suitable to achieve the intended purpose. In particular embodiments, the structural pallet segments may be different shapes. In particular embodiments, the structural pallet segments are selected from any polygon or non-polygon (e.g., circles, ovals, or other more custom shapes). In a specific embodiment, the structural pallet segments are selected from any polygon.

In certain embodiments of the present invention, the structural pallet segments are hexagonal (e.g., presenting six facets)

In certain embodiments of the present invention, all of the slip-lock cavities are identical in shape.

In certain embodiments of the present invention, all of the slip-lock anchors are identical in shape.

In certain embodiments of the present invention, the different paired slip-lock anchors and slip-lock cavities are differently sized or shaped, i.e., such that one paired slip-lock anchor with a slip-lock cavity may be different in size and/or shape than another slip-lock anchor paired with a slip-lock cavity.

In certain embodiments of the present invention, all of the slip-lock anchors are shaped like an arrowhead (e.g., see FIG. 2 ).

In certain embodiments of the present invention, the physical support pad is a fitness mat.

In certain embodiments of the present invention, the physical support pad is a yoga mat or yoga accessory.

In certain embodiments of the present invention, the pad thickness may be selected from a thickness between about ⅜ inch and about 1 inch. In particular embodiments, the pad thickness may be selected from a thickness between about ⅜ inch and about ½ inch. In particular embodiments, the pad thickness may be selected from a thickness between about ½ inch and about ¾ inch.

In certain embodiments of the present invention, the pad diameter across any axis of symmetry may be selected from a diameter between about 10 inches and about 24 inches.

In certain embodiments of the present invention, the pad diameter across any axis of symmetry about 20 inches.

In certain embodiments of the present invention, the expanded polyurethane foam is characterized by at least one of the following properties (e.g., all of the following properties)

-   -   (a) bulk density of foam beads is about 100 to 150 kg/m³;     -   (b) particle size is about 2 to 12 mm;     -   (c) average bead weight is 26+/−3 mg;     -   (d) molded core density is 220-320 kg/m³;     -   (e) rebound rate >about 63% (e.g., rebound rate >65%);     -   (f) excellent cleanability, e.g., machine washable;     -   (g) dimensional stability at low and high temperatures (e.g.,         high elasticity and softness even at about −25° C.);     -   (h) anti-yellowing (e.g., non-yellowing);     -   (i) excellent abrasion resistance (e.g., very low abrasion);     -   (j) tensile strength kPa 600;     -   (k) elongation at break (e.g., avg. 70%)     -   (l) low compression set (e.g., compressed reply >about 96%)     -   (m) water uptake (24 hours @ 23° C.)<1%;     -   (n) dual surface, anti-slip textures;     -   (o) various colors available;     -   (p) high elasticity >55% rebound; and     -   (q) eco-friendly material (e.g., 100% recyclable or         re-purposable).

In certain embodiments of the present invention, the pad comprises an anti-slip surface, e.g., two anti-slip surfaces. In certain embodiments, the pad comprises an anti-slip surface based on the properties of the surface material, e.g., wherein the skived surface of the expanded polyurethane foam provides an anti-slip surface. In certain embodiments, the pad comprises an anti-slip surface based on molded surface texture, e.g., wherein an anti-slip design may be enhanced to create a mold/tool that offers an anti-slip texture. In particular embodiments, the anti-slip properties are improved in comparison with convention ethylene-vinyl acetate foam rectangular or puzzle piece mats.

A. First Structural Pallet Segment

The physical support pads of the present invention comprise a first structural pallet segment shaped to incorporate a slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity.

The shape of the anchor toggles may be any shape suitable to achieve the intended function of the anchor toggles which act to flex/toggle when the slip-lock anchor is longitudinally moved inward into the slip-lock cavity and afford interlocking with the anchor toggles and are positioned under/outside of the anchor tabs to fix the position of the slip-lock anchor. These extended projections are balanced in size to offer longitudinal inward access by the slip-lock anchor, suitable strength to support interlocking the slip-lock anchor in the slip-lock cavity and reducing unintended separation, and suitable to move longitudinally outward when the designed release force exceeds the force required to (longitudinally) flex one or two of the anchor tabs. The size of the anchor toggles effects the release force, and will be selected according to the above-listed factors and the desired release force (which may be affected by the structural properties of the material). In particular embodiments, the anchor toggles may be triangular or similar custom shapes with non-polygonal edges, such as curves.

In certain embodiments of the present invention, the first structural pallet segment is shaped to incorporate a second or third slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity.

In certain embodiments of the present invention, the first structural pallet segment further comprises one or more additional slip-lock cavities. In certain embodiments, the additional cavity is shaped or sized different that the first slip-lock cavity.

In certain embodiments of the present invention, the first structural pallet segment shaped to incorporate a second or third slip-lock anchor defined to match the second or third slip-lock cavity, comprising two anchor tabs on each side of the second or third slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles of the second or third slip-lock cavity and the anchor tabs of the second or third slip-lock anchor are adjacent when the paired pallet segments are in interlocked position.

In certain embodiments of the present invention, the first structural pallet segment further comprises one or more additional slip-lock anchors. In certain embodiments, the additional anchor is shaped or sized different that the first slip-lock anchor.

B. Second Structural Pallet Segment

The physical support pads of the present invention comprise a second structural pallet segment is shaped to incorporate a slip-lock anchor defined to match the slip-lock cavity of the first structural pallet segment comprising two anchor tabs on each side of the slip-lock anchor, wherein the anchor tabs of the second structural pallet segment are positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position.

In certain embodiments of the present invention, the second structural pallet segment shaped to incorporate a fourth slip-lock anchor defined to match the first, second, or third slip-lock cavity, comprising two anchor tabs on each side of the fourth slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles of the first, second, or third slip-lock cavity and the anchor tabs of the fourth slip-lock anchor are adjacent when the paired pallets are in interlocked position.

The shape of the anchor tabs may be any shape suitable to achieve the intended function of the anchor tabs which act to flex/toggle the anchor toggles of the slip-lock cavity when the slip-lock anchor is longitudinally moved inward into the slip-lock cavity and afford interlocking with the anchor toggles that are positioned under/outside of the anchor tabs to fix the position of the slip-lock anchor. In particular embodiments, the anchor tabs may be triangular or similar custom shapes with non-polygonal edges, such as curves.

In certain embodiments of the present invention, the second structural pallet segment further comprises one or more additional slip-lock anchors.

In certain embodiments of the present invention, the second structural pallet segment is shaped to incorporate a fourth slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity.

In certain embodiments of the present invention, wherein the second structural pallet segment further comprises one or more additional slip-lock cavities.

C. Additional Structural Pallet Segments

In certain embodiments of the present invention, the physical support pad constructed as a paired pallet slip-lock system further comprises one or more additional structural pallet segments (e.g., paired structural pallet segments), wherein each additional structural pallet segment comprises at least one of:

-   -   a slip-lock cavity, e.g., a second slip-lock cavity, as         described in certain embodiments of the present invention; or     -   a slip-lock anchor, e.g., second slip-lock anchor, as described         in certain embodiments of the present invention.

Another embodiment of the present invention provides a physical support pad constructed as a paired pallet slip-lock system comprising at least two structural pallet segments of expanded polyurethane foam wherein the two structural pallet segments comprise

-   -   a first structural pallet segment shaped to incorporate a         slip-lock cavity defined by a narrowing cavity with two anchor         toggles positioned one on each side of the cavity; and     -   a second structural pallet segment shaped to incorporate a         slip-lock anchor defined to match the slip-lock cavity         comprising two anchor tabs on each side of the slip-lock anchor,         wherein the anchor tabs are positioned such that the anchor         toggles and the anchor tabs are adjacent when the paired pallet         segments are in interlocked position;     -   wherein the first and second structural pallets are suitably         flexible such that the slip-lock anchors of the second         structural pallet segment may longitudinally slip past the         anchor toggles of the first structural pallet segment to         interlock as a paired pallet, and wherein the two segments         longitudinally separate only when the release force exceeds the         force required to longitudinally flex one or more of the anchor         toggles or the anchor tabs, and further comprising one         additional structural pallet segment (e.g., paired structural         pallet segment), wherein the additional structural pallet         segment comprises at least one of:     -   a slip-lock cavity, e.g., a second slip-lock cavity, as         described in certain embodiments of the present invention; or     -   a slip-lock anchor, e.g., second slip-lock anchor, as described         in certain embodiments of the present invention.

III. Travel Physical Support Pads of the Invention

The physical support pads of the present invention, wherein the pad diameter across any axis of symmetry is of suitable diameter to be convenient for storage and/or transport while travelling. For example, such travel physical support pads of the invention may be easy to carry and/or may fit inside a small travel bag.

As such, another embodiment of the present invention provides a travel physical support pad. Such travel physical support pad comprises a physical support pad of the present invention, wherein the pad diameter across any axis of symmetry is about 10 inches to about 20 inches, e.g., about 10 inches. In certain embodiments, the pad thickness is about ⅜ inch.

In certain embodiments of the travel physical support pads of the present invention, at least one of the two structural pallet segments of expanded polyurethane foam may be comprised of two or more, e.g., three, pieces that are assembled to produce the structural pallet segment. Such separate components of a structural pallet segments are more easily carried during travel. In certain embodiments, the assembly may be through a slip-lock cavity receipt of a slip-lock anchor. In certain embodiments, the assembly may be through well-known puzzle interlock connections.

IV. Physical Support Pad Expansion Kits of the Invention

The physical support pads of the present invention may require expansion or replacement of a paired structural pallet segment of expanded polyurethane foam. Such additional structural pallet segments may be supplied in kits comprising one or more expansion structural pallet segments for use in conjunction with another physical support pad of the present invention.

As such, another embodiment of the present invention provides a physical support pad expansion kit comprising one or more expansion structural pallet segments for use in conjunction with another physical support pad of the present invention, wherein each expansion structural pallet segment comprises at least one of:

-   -   a slip-lock cavity, as described in certain embodiments of the         present invention; or     -   a slip-lock anchor, as described in certain embodiments of the         present invention.

V. Method of Manufacture of Physical Support Pads of the Invention

In certain embodiments of the present invention, the physical support pads of the invention may be formed by molding or by cutting, or a combination of both. In certain embodiments, the expanded polyurethane foam is selected from one or more of a polyether polyurethane, a polyester polyurethane, a polycarbonate polyurethane, and a polycaprolactone polyurethane. In a particular embodiment, the expanded polyurethane foam is e-TPU. In another particular embodiment, the expanded polyurethane foam is an expanded thermoset polyurethane, e.g., a free-rise elastomeric polyurethane.

For example, skived or molded layers may be cut into shapes according to the present invention. In particular, the layers may be cut into structural pallets shaped to incorporate a slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity. In particular, the layers may be cut into structural pallets shaped to incorporate a slip-lock anchor defined to match the slip-lock cavity comprising two anchor tabs on each side of the slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position.

In certain embodiments, an antibacterial agent, e.g., 2-4% of an antibacterial agent, may be added to afford antibacterial properties. In particular embodiments, the antibacterial agent may be selected from a metal antibacterial agent (e.g., metal oxide such as zinc oxide or magnesium oxide; silver, copper, zinc and inorganic salts and complexes thereof, such as pyridine zinc thione, silver-loaded zirconium phosphate, and the like) or an organic antibacterial agent, e.g., chitosan.

In certain embodiments, a fire retardant agent may be added to afford fire retardant properties.

In certain embodiments, a UV stabilizer agent may be added to afford UV stabilization properties.

In certain embodiments, a custom color agent may be added to afford a custom color.

The physical support pads of the present invention may be tested for properties including specific gravity, hardness, resilience, folding resistance, adhesive strength, antibacterial properties and the like.

A. e-TPU

In certain embodiments of the present invention, the physical support pads of the invention may be formed by e-TPU steam molding from e-TPU particles. For example, in certain embodiments, the e-TPU particles may be prepared by using e-TPU particles, e.g., with a particle size of 2-4 mm, and a supercritical carbon dioxide rapid pressure-reduction method with physical foaming using the principle of gas phase differentiation, e.g., using supercritical carbon dioxide as a foaming agent, where e-TPU foamed particles may be prepared by intermittent pressure release heating. In a particular embodiment of the present invention, the carbon dioxide gas is introduced into the reaction vessel to increase the pressure in the reaction vessel to 15 MPa, and the temperature is raised to 50° C., so that the carbon dioxide reaches a supercritical state and the composite material is infiltrated for 1.5 hours. The pellets of the infiltrated composite material may be quickly placed in a foaming apparatus and heated to 110° C. to foam, and the foamed particles may be expanded numerous times, e.g., 8 times.

In certain embodiments of the present invention, the e-TPU particles may be obtained from recycled material, e.g., recovered from previously molded particles.

In certain embodiments, the prepared expanded thermoplastic polyurethane particle foam particles are placed in a steam molding device by steam compression molding to prepare a plate mold having a defined thickness. In particular, this technology uses steam to weld foam into components, for example, through the diffusion and entanglement of molecular chains at the interface, the small TPU molecules made of solid particles are expanded like popcorn, and the beads are bonded in the mold to be processed into a product of the desired shape/mold. The prepared plate mold is cut into several pieces by using a slicer and skived to create layers of smaller thickness, e.g., between about ⅜ inch and about 1 inch, e.g., between about ⅜ inch and about ½ inch.

In certain embodiments, the process of steam molding includes injecting the foamed particles into a molding die, introducing high temperature steam into the mold, where the high temperature steam passes through the forming mold for a period of time and then is cooled into a cooling water setting. In particular embodiments, the steam pressure is 0.1-0.4 MPa, the steam penetration time is 40-160 s, and the mold cavity is sealed and is 10-16 mm, the dwell time is 40-120 s, the cooling water flow rate is 0.1-0.2 m³/h, and the water-cooling setting time is 40-120 s. In particular embodiments, the steam pressure is 0.3 MPa, the steam penetration time is 100 s, and the mold cavity is 10-16 mm, the dwell time is 40 s, the cooling water flow rate is 0.1 m³/h, the water cooling setting time is 100 s, and the plate having a thickness of 1.6 cm is obtained after molding.

B. Thermoset Polyurethane

In certain embodiments of the present invention, the physical support pads of the invention may be formed by cutting/skiving expanded thermoset polyurethane. Methods of manufacture are well-known in the art, and such methods are incorporated herein by reference thereto. In certain embodiments, the expanded thermoset polyurethane is prepared from a two component mixture (e.g., water blown), and allowed to free-rise to form the CO₂ expanded elastomeric polyurethane, and is subsequently skived into layers and/or a desired shape.

V. Design Aspects of the Invention

Independent of the utility related to the containers of the present invention, the ornamental appearance of any novel design provided herein is intended to be part of this invention, for example, each of the perspective views in FIGS. 1 to 7 , which may form an independent or combined ornamental appearance of the physical support pads described herein.

Accordingly, one embodiment of the present invention provides an ornamental design for a physical support pad as shown and described.

EXEMPLIFICATION

Having thus described the invention in general terms, reference will now be made to exemplary embodiments, and the accompanying drawings of exemplary embodiments, which are not necessarily drawn to scale, and which are not intended to be limiting in anyway.

In this respect, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the Figures. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

Example 1 Exemplary Embodiments: Arrowhead Slip-Lock System

An exemplary embodiment of the present invention comprises an arrowhead shaped slip-lock system of expanded polyurethane foam. FIG. 1 depicts a top down perspective of an exemplary first structural pallet segment 1 shaped to incorporate a slip-lock cavity 2 defined by a narrowing cavity with two anchor toggles 3 positioned one on each side of the cavity 2. FIG. 2 depicts a top down perspective of an exemplary second structural pallet segment 6 shaped to incorporate a slip-lock anchor 4 defined to match the slip-lock cavity 2 comprising two anchor tabs 5 on each side of the slip-lock anchor 4.

FIG. 3 depicts a top down perspective of an interlocking paired pallet showing the first structural pallet segment 1 and the second structural pallet segment of 6 interlocking wherein the first 1 and second 6 structural pallets are suitably flexible such that the slip-lock anchor 4 of the second structural pallet segment 6 may longitudinally slip past the anchor toggles 3 of the first structural pallet segment 1 to interlock as a paired pallet wherein the anchor tabs 5 will be positioned such that the anchor toggles 3 and the anchor tabs 5 are adjacent when the paired pallet segments are in interlocked position. FIG. 4 depicts the top down perspective of the interlocked paired pallet showing the first structural pallet segment 1 and the second structural pallet segment of 6 interlocked as a paired pallet wherein the anchor tabs 5 are positioned such that the anchor toggles 3 and the anchor tabs 5 are adjacent when the paired pallet segments are in interlocked position. The white space depicts the connection in an overemphasized way to more clearly see the paired pallets.

The two interlocked paired pallet segments may longitudinally separate as in FIG. 5 when the release force exceeds the force required to longitudinally flex or toggle one or more of the anchor toggles 3 outward as indicated by the arrow showing outward directional toggling and the double arrow showing the longitudinal separation of the interlocked pallets.

Example 2 Exemplary Embodiments: Hexagon Pallets with Arrowhead Slip-Lock System

An exemplary embodiment of the physical support pads of the invention are constructed as a paired pallet slip-lock system comprising at least two structural pallet segments of expanded polyurethane foam. A single structural pallet segment 8 is depicted in FIG. 6 as hexagonal and shaped to incorporate a slip-lock cavity 9 defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity; and shaped to incorporate a slip-lock anchor 7 defined to match the slip-lock cavity comprising two anchor tabs on each side of the slip-lock anchor.

FIG. 7 depicts a top down perspective of two hexagonal structural pallet segments of FIG. 6 interlocking, wherein the anchor tabs will be positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position.

INCORPORATION BY REFERENCE

The entire contents of all patents, published patent applications and other references cited herein are hereby expressly incorporated herein in their entireties by reference.

EQUIVALENTS

Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents were considered to be within the scope of this invention and are covered by the following claims. Moreover, any numerical or alphabetical ranges provided herein are intended to include both the upper and lower value of those ranges. In addition, any listing or grouping is intended, at least in one embodiment, to represent a shorthand or convenient manner of listing independent embodiments; as such, each member of the list should be considered a separate embodiment. 

What is claimed is:
 1. A physical support pad constructed as a paired pallet slip-lock system comprising at least two structural pallet segments of expanded polyurethane foam wherein the two structural pallet segments comprise a first structural pallet segment shaped to incorporate a slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity; and a second structural pallet segment shaped to incorporate a slip-lock anchor defined to match the slip-lock cavity comprising two anchor tabs on each side of the slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles and the anchor tabs are adjacent when the paired pallet segments are in interlocked position; wherein the first and second structural pallets are suitably flexible such that the slip-lock anchors of the second structural pallet segment may longitudinally slip past the anchor toggles of the first structural pallet segment to interlock as a paired pallet, and wherein the two segments longitudinally separate only when the release force exceeds the force required to longitudinally flex one or more of the anchor toggles or the anchor tabs.
 2. The physical support pad of claim 1, further comprising one or more additional structural pallet segments, wherein each additional structural pallet segment comprises at least one of: a second slip-lock cavity; or a second slip-lock anchor.
 3. The physical support pad of claim 2, wherein each slip-lock cavity and slip-lock anchor are positioned on different facets of the structural pallet segments.
 4. The physical support pad of claim 1, wherein the structural pallet segments are hexagonal.
 5. The physical support pad of claim 2, wherein the first structural pallet segment is shaped to incorporate a third slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the third slip-lock cavity.
 6. The physical support pad of claim of claim 2, wherein the first structural pallet segment further comprises one or more additional slip-lock cavities.
 7. The physical support pad of claim 5, wherein the first structural pallet segment shaped to incorporate a third slip-lock anchor defined to match the second or third slip-lock cavity, comprising two anchor tabs on each side of the third slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles of the second or third cavity and the anchor tabs of the third slip-lock anchor are adjacent when the paired pallet segments are in interlocked position.
 8. The physical support pad of claim 1, wherein the first structural pallet segment further comprises one or more additional slip-lock anchors.
 9. The physical support pad of claim 7 wherein the second structural pallet segment shaped to incorporate a fourth slip-lock anchor defined to match the first, second, or third slip-lock cavity, comprising two anchor tabs on each side of the fourth slip-lock anchor, wherein the anchor tabs are positioned such that the anchor toggles of the first, second, or third slip-lock cavity and the anchor tabs of the fourth slip-lock anchor are adjacent when the paired pallets are in interlocked position.
 10. The physical support pad of claim 2, wherein the second structural pallet segment further comprises one or more additional slip-lock anchors.
 11. The physical support pad of claim 9, wherein the second structural pallet segment is shaped to incorporate a fourth slip-lock cavity defined by a narrowing cavity with two anchor toggles positioned one on each side of the cavity.
 12. The physical support pad of claim 2, wherein the second structural pallet segment further comprises one or more additional slip-lock cavities.
 13. The physical support pad of claim 1, wherein all of the slip-lock anchors are shaped like an arrowhead.
 14. The physical support pad of claim 1, wherein the physical support pad is a fitness mat.
 15. The physical support pad of claim 1, wherein the physical support pad is a yoga mat or yoga accessory.
 16. The physical support pad of claim 1, wherein the pad thickness may be selected from a thickness between about ⅜ inch and about 1 inch.
 17. The physical support pad of claim 1, wherein the pad diameter across any axis of symmetry may be selected from a diameter between about 10 inches and about 24 inches.
 18. The physical support pad of claim 1, wherein the expanded polyurethane foam is characterized by at least one of the following properties (a) bulk density of foam beads is about 100 to 150 kg/m³; (b) particle size is about 2 to 12 mm; (c) average bead weight is 26+/−3 mg; (d) molded core density is 220-320 kg/m³; (e) rebound rate >about 63%; (f) excellent cleanability; (g) dimensional stability at low and high temperatures; (h) anti-yellowing; (i) excellent abrasion resistance; (j) tensile strength kPa 600; (k) elongation at break; (l) low compression set; (m) water uptake <1%; (n) dual surface, anti-slip textures; (o) various colors available; (p) high elasticity >55% rebound; and (q) eco-friendly material.
 19. The physical support pad of claim 1, wherein the pad comprises an anti-slip surface.
 20. A travel physical support pad of claim 1, wherein the pad diameter across any axis of symmetry is about 10 inches.
 21. The travel physical support pad of claim 24, wherein the pad thickness is about ⅜ inch.
 22. A physical support pad expansion kit comprising one or more expansion structural pallet segments for use in conjunction with the physical support pad of claim 1, wherein each expansion structural pallet segment comprises at least one of: a slip-lock cavity; or a slip-lock anchor. 